Project goal: To automate the sponsor’s capacity-planning system by implementing an accessible and user-friendly web-based form.The sponsor runs an error-prone manual capacity-planning system using Microsoft Excel. The designed system includes back end and laser-marking capacity planning. An analysis of the sponsor’s current method was done in MatLab, and a simulation of the capacity planning was produced. The simulation was used to learn how to convert, process and interface the required information into a website. The designed web form consists of hypertext markup language graphic interfaces, C# back end computation, and an Oracle database that manages the data storage and interfaces with the web form using Structured Query Language. The web form allows multiple departments, such as human resources and sales, to enter data directly into the system within a certain time frame before a supervisor is notified via automated message. The system also checks if the input values fall within acceptable bounds.

Project goal: To design, build and test a robotic quality-assurance system to streamline the sponsor’s manufacturing process. The team designed a collaborative robot vision system integration consisting of a robotic arm integrated with visual part recognition, quality assurance, data logging, and part packaging. Each part being analyzed has a barcode that is scanned and logged in the packaging history. The designed system verifies,using 3-D analysis point clouds,that part pin dimensions and spacing meet the sponsor’s design parameters. The system chooses parts from an incoming supply, inspects them for quality assurance, and places them in either a packaging carton or a disposal bin. Continuous processing is achieved by a gravity-fed chute system. Empty input containers and full output containers are pushed aside by the robot arm to make way for fresh containers. The system is ready for implementation in the sponsor’s factory.

Project goal: To design, build and test a device to maintain the ideal temperature range of a solar panel and display the efficiency data on a remote device. Solar panels potentially produce the most power during summer but heat decreases their efficiency as panel temperature climbs above optimal operating range. The cooling system design uses a Peltier module to distribute a temperature difference across the panel, which enables the cooling system to increase the heat rate through the panel and accelerate heat ejection to its surroundings. While monitoring the changes in power efficiency and temperature, sensors relay data to a cloud-based server. This data is then presented to the user for review on a mobile application, which allows the user to view stored data, control system power, and monitor sensor errors.

Project goal: To create a new USB point-of-sale hub that interfaces with existing peripherals and an iPad through a microprocessor. The peripherals consist of a card reader, scanner, display, printer and cash drawer. The system translates the data collected from the scanner or card reader and displays it on the iPad. The system also takes data from the iPad and outputs it to a display or printer. The entire system meets the requirements of Apple’s Made for iPhone/iPod/iPad licensing program, and the app serves as an iOS demonstration program for the testing of the four peripherals.

Project goal: To design, build and test a motorized reel system that allows rescuers to bring the EMILY unit and drowning survivors back to shore. A shortcoming of the Emergency Integrated Lifesaving Lanyard, or EMILY, developed by the sponsor for rapid deployment to save people from drowning, is that it cannot bring survivors back to shore. Research, testing and data analysis were performed to determine the loads that the reel system would experience during a water rescue. Sponsor requirements included that the system weigh no more than 50 pounds and be portable by one person, and that it can operate in extreme heat and salt-water environments, which limited the materials that could be used. Evaluation of the selected materials’thermal resistance, corrosion resistance and overall tensile strength was conducted to determine the best option. The information obtained was used to select a motor and develop the variable-speed controller, which maintains a constant speed during retrieval. The tests showed that as the rope is winched in, the increase in reel diameter increases the speed by more than two miles per hour. Limited system tests were performed to verify performance requirements.

Project goal: To design, build and test a celestial GPS antispoofing system to detect whether a satellite GPS signal has been spoofed. The system must perform at night in an ocean environment without communication to off-board systems in order to avoid providing potentially biased results to the operator. The antispoofing system uses images from an on-board camera, celestial mapping software,and image comparison software. All components, including a microprocessor to store the software, are housed in a custom waterproof case that can be mounted to the sponsor’s autonomous aquatic rescue craft, EMILY, which stands for Emergency Integrated Lifesaving Lanyard. The celestial mapping software produces an image of the celestial bodies that should appear overhead for a given time and location, while the image processor makes a comparison with the predicted celestial map to detect the presence of spoofing. Test images of the night sky were captured over several months and a variety of weather conditions, and used as tools for the development and functional validation of the image processing software.

Project goal: To design and construct an alignment guide that for use in preliminary positioning and fixation of a surgical resection guide during total ankle arthroplasty procedures. Alignment of the resection guide to the mechanical axis of the patient’s leg is crucial to proper bone removal for the implantation of an ankle prosthesis. Incorrect placement and malalignment of an ankle prosthesis can lead to severe complications in postoperative ambulation due to improper load bearing of the joint. This device has been developed to be more accurate and less invasive than other products currently available. The mechanical alignment guide system consists of several custom-designed parts making up many common mechanical systems, such as a modified rack and pinion, hinge joint, and slider. Alignment of the system is completed about six degrees of freedom with tolerances of 2 mm and 2 degrees of three anatomical axes. A compact, easy-to-use design capable of withstanding multiple forms of sterilization has been implemented and proper use of the alignment guide is detailed in a surgical technique to be used by physicians.

Project goal: To design a fully autonomous parachute system for an unmanned aircraft system in distress. The design required trade-offs between material and system performance. Iterative testing established the most effective ejection method, and mathematical models determined the appropriate parachute size to meet the requirement for descent rate. Microcontroller firmware was written to filter and analyze the real-time sensor data. If the unmanned aircraft system exceeds manufacturer-specified flight envelope limits, the spring-loaded system rapidly ejects a parachute. The electronics package uses off-the-shelf sensor components and a commonly used microcontroller. The parachute is made of thin rip-stop nylon strung with a combination of nylon and paracord. The entire system is contained in a custom plastic enclosure mounted to the unmanned aircraft system. A functioning prototype was built using 3-D printed components. The design is based on the commercially available DJI Phantom, but is scalable for larger and heavier models and differing impact speeds.

Project goal: To create a gait simulator to study how changes in foot alignment resulting from surgery or fractures affect pressure in foot joints. Realistic gait is achieved by simulated muscle contractions created by linear actuators attached to each of four tendons. The system consists of the material testing system, the actuator assembly, and the computer software program that controls actuator sequencing. The material testing system provides axial loading on the foot during the simulated gait cycle. The system includes a graphical user interface that creates flexibility by allowing changes to amplitude of force applied by actuators, speed of actuator loading,and synchronization of the gait simulator and actuator control systems.

Project goal: To design, build and test a prototype of a low-cost monitoring system to provide 360-degree thermal and visual field surveillance of an electrical substation. High-resolution thermal imaging is an informative yet expensive imaging technique to monitor electrical substation performance. The designed system provides security and monitors high-voltage equipment life to prevent component failure. The system transmits visual and thermal video data to a server, and a graphical user interface displays the two video feeds and graphical thermal data. The design allows the camera system to operate with a cost-effective long-wave infrared system that output an improved resolution in long-wave infrared up to 640 by 480 pixels,and dual camera long-wave infrared/visible feed for security and thermal data purposes.